Advantages and Disadvantages of Injection Moulding?

Injection molding is a process commonly utilized to produce plastic components in high volumes. This procedure is not only cost-effective, it also allows for better quality.However, prior to injection molding, it is important to understand the various design restrictions that are necessary to ensure the proper operation of the process.

Advantages and Disadvantages of Injection Molding

Although the following guidelines apply to conventional injection molding, they may make it difficult for individuals with limited resources to develop products with low numbers.

Low volume production possibilities

The good news is that TEAM MFG has developed strategies and techniques to overcome some of the issues that previously prevented them from producing certain parts.Aside from being able to produce low volume parts, we also make injection molding more cost-effective for much lower quantities. Through a hybrid approach, we are able to provide a mould tool that fits to the client's requirements.The result is a mould tool that reflects the requirement and opens up an exciting option to produce high quality, yet low volume components.

Advantages of injection moulding

1)Fast production and highly efficient.

Depending on the complexity of the mould and the size of the component, the injection process can produce up to 120 parts per hour.

2)Low labour costs.

Automated plastic injection molding is a process that's performed by robots and machines. This method allows a sole operator to control and manage the production process.

3)Design flexibility.

The high pressure forces the plastic components to become more difficult to shape. This process allows for more intricate designs to be made.

4)High-output production.

Thousands of parts can be produced before the tooling needs to be maintained.

5)Large material choice.

There are a variety of resin options to choose from, such as PP, ABS, and TPE. These can be combined with other plastic materials for an improved product.

6)Low scrap rates.

Unlike traditional manufacturing processes, injection molders don't generate much waste after the production of the finished product. Instead, they recycle the unused plastic.

7)Ability to include inserts.  

Metal or plastic inserts can be insert moulded.

8)Good colour control.

Plastic parts can be manufactured in any required colours with the use of masterbatches or compounding.

9)Product consistency.

This process is also known to produce parts that are consistent in quality. This eliminates the possibility of having two batches of parts that are identical.

10)Reduced finishing requirements.

There is often very little post-production work required as parts usually have a good finished look upon ejection.

11)Enhanced Strength.

When used in conjunction with the molding process, fillers can help improve the strength of the finished product.In addition, fillers can help improve the overall strength of the finished product by reducing the density of the plastic.

Disadvantages of injection moulding

1)High tooling costs and long set up lead times.

The initial costs of injection moulding are usually high due to the various stages involved. Aside from the design and prototype, a part also has to be tested and replicated in order to be injection molded.

2)Part design restrictions.

Plastic parts must be designed with injection moulding consideration and must follow the basic rules of injection moulding, for example:

● Avoid undercuts and sharp edges as much as possible

● Use uniform wall thicknesses to prevent inconsistencies in the cooling process resulting in defects like sink marks.

● Draft angles are encouraged for better de-moulding.

Since tools are usually made from steel or aluminum, it can be difficult to change the design of a part without affecting its appearance. However, in order to get rid of plastic, you need to reduce the size of the tool cavity.This usually involves taking out the plastic part and adding metal or aluminum to the cavity. Doing this can be very challenging and might require the use of a new tool.The size and weight of the part will determine the size of the tool and the press size.

3)Small runs of parts can be costly.

Due to the complexity of the process and the need to get rid of all the previous material, many companies consider small runs of parts as too expensive to injection moulding.

In summary

Although it uses a lot of materials and colors, injection moulding is still a great process for creating complex parts. Its tight tolerance and repeatable nature make it a good choice for most applications.Although it uses a lot of materials and colors, injection molding is still a good choice for creating complex parts. Its tight tolerance and repeatable nature make it a good choice for most applications. Contact TEAM MFG today to learn more now!